Flexible pouch with flat seam and method of forming

ABSTRACT

A flexible pouch with a flat seam for containing a product and a method of forming the pouch is provided. The pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween. One side edge is positioned over the second edge and sealed to form a flat seam that lies flat against the outer surface of the panel. An upper edge of the pouch includes a first ultrasonic closing seal, and a second seal is positioned above the first closing seal. The pouch also includes opening means integral with the panel for accessing a product contained within the pouch.

RELATED APPLICATION

This application claims priority of U.S. Provisional Patent ApplicationSer. No. 60/598,394 filed Aug. 3, 2004, which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a flexible pouch forpackaging a product and, more specifically, to a flexible pouch with aflat seam for packaging a product and a method of manufacturing thesame.

2. Description of the Related Art

Various types of disposable, portable containers are known in the artfor storing a fluid or dry product, such as a liquid, granular material,powder or the like. Examples of containers include a cup, a metal can, aplastic bottle, a glass bottle or a flexible pouch. Consumers prefer theconvenience of flexible pouches over other types of containers due totheir shape, size, shelf life and storage adaptability. Manufacturersrecognize the packaging benefits of a flexible pouch, since the pouchcan be formed and filled on the same manufacturing line. An example of amethod and apparatus for filling a flexible pouch with a product isdisclosed in commonly assigned U.S. Pat. No. 6,199,601, which isincorporated herein by reference.

Flexible pouches have been used for some time to distributenon-carbonated beverages, such as fruit juice and the like. However,their use with other types of beverages, including carbonated beverages,has been limited. With respect to carbonated beverages, the presentlyavailable materials are somewhat permeable, thereby allowing loss of theinternal carbon dioxide gas from the pouch and its replacement withoxygen. The presence of oxygen in the filled pouch increases the chanceof bacteria forming, or may affect the taste. An example of a pouch fora carbonated beverage is disclosed in commonly assigned PCT PatentApplication No. PCT/US03/034396, which is incorporated herein byreference.

The flexible pouch is made from a flexible material, preferably alaminate composed of sheets of plastic or aluminum or the like. An outerlayer of the material may include preprinted information, such as a logoor the like, to provide the consumer with information regarding thecontents of the pouch. The pouch may be formed and/or filled usingconventionally known manufacturing techniques, such as a horizontalform-fill-seal machine with a single or multiple lanes, a flat bedpre-made pouch machine, a vertical form-fill machine, or the like. Thepouch includes a front panel joined to a back panel. Edges of thepanels, such as a side edge, are joined together using a sealingtechnique such as bonding or welding. The sealed edge resembles a fin.

While the above-described pouch functions well, the exposed “fin” edgemay be sharp. Also, the potential shapes for the pouch are limited usinga “fin” edge. Thus, there is a need in the art for a flexible pouch witha flat seam, and an improved method of making a flexible pouch with aflat seam that can be used to hold various types of products.

SUMMARY OF THE INVENTION

Accordingly, the present invention is an improved flexible pouch with aflat seam for a product and a method for manufacturing the pouch. Thepouch includes a panel having an inner surface and an outer surface, andan upper edge, an opposed lower edge and two side edges extendingtherebetween. One side edge is positioned over the second edge andsealed to form a seam that lies flat against the outer surface of thepanel. An upper edge of the pouch includes a first ultrasonic closingseal, and a second closing seal is positioned above the first closingseal. The pouch also includes an opening means integral with the panelfor accessing a product contained within the pouch.

The method includes the steps of forming a pouch by forming a fold alongeach side edge of the panel and positioning the panel so that the foldin each side edge is aligned and the first side edge extends beyond thesecond side edge. The extending portion of the first side edge is foldedover the second edge to form a flap, and is sealed. The lower edge ofthe pouch is sealed. The flap may be tacked down to the lower edge andupper edge of the pouch during the sealing step, so that the flap liesflat against the walls of the pouch. The flap may also be sealed to theouter surface of the pouch using a cover strip. The flap may also befolded into the inside of the pouch or formed into a side gusset.

One advantage of the present invention is that a flexible pouch with aflat seam and an improved method of making the flexible pouch isprovided. Another advantage of the present invention is that a flexiblepouch and method of making a flexible pouch is provided that utilizes alaminate material that includes PET, foil, nylon and cast polypropylene.Still another advantage of the present invention is that a flexiblepouch and the method of making a flexible pouch is provided thatincludes a flat seam with edges that overlap. A further advantage of thepresent invention is that a flexible pouch and method of making aflexible pouch is provided that includes a flat seam with edges thatfold over to form a flap, and the flap lies flat against the pouch withno sharp edges. Still a further advantage of the present invention is aflexible pouch and a method of making a flexible pouch filled with aproduct is provided that is cost effective to manufacture. Yet a furtheradvantage of the present invention is that the flexible pouch retainsits shape as the product is removed. Still yet a further advantage ofthe present invention is that the flexible pouch includes an insert sothat it can stand upright unsupported. Another advantage is that thepouch stands up and is made of a laminate material with an openingmeans.

Other features and advantages of the present invention will be readilyappreciated, as the same becomes better understood after reading thesubsequent description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a flexible pouch with a flat seam,according to the present invention.

FIG. 2 a is an elevational view of a flexible pouch with a folded flatseam according to the present invention.

FIG. 2 b is a perspective side view illustrating a folded flat seam forthe pouch of FIG. 1, according to the present invention.

FIG. 2 c is a partial elevational view of a flexible pouch with a foldedflat seam, according to the present invention.

FIG. 3 is an elevational view of a panel with an integrally formedgusset prior to sealing the side edges, according to the presentinvention.

FIG. 4 a is an elevational view of a pouch having an integrally formedgusset and an overlap flat seam, according to the present invention.

FIG. 4 b is a detail view of the overlap flat seam, according to thepresent invention.

FIG. 5 is a side view of a flexible pouch with a seal strip covering theflat seam, according to the present invention.

FIG. 6 a is an elevational view of a stand-up flexible pouch with a flatseam, tear notch and insert, according to the present invention.

FIG. 6 b is an end view of the pouch of FIG. 6 a, according to thepresent invention.

FIG. 6 c is a partial view of an insert for the pouch of FIG. 6 a,according to the present invention.

FIG. 7 a is an elevational view of a stand-up flexible pouch with a flatseam, straw hole, pull tab opening means and insert, according to thepresent invention.

FIG. 7 b is a top view of an insert with a pull tab and straw hole,according to the present invention.

FIG. 7 c is a cutaway view of an insert, according to the presentinvention.

FIGS. 8 a and 8 b are partial views of a stand-up flexible pouch with aflat seam, fitment and side gussets, according to the present invention.

FIGS. 9 a-9 c are an elevational view of a stand-up flexible pouch witha flat seam, fitment and insert, according to the present invention.

FIG. 10 is another elevational view of a stand-up flexible pouch with aflat seam and fitment, according to the present invention.

FIGS. 11 a-11 d are elevational views of stand-up caps for the flexiblepouch with fitment, according to the present invention.

FIG. 12 is a flowchart of a method of forming a flexible pouch with aflat seam, according to the present invention.

FIG. 13 is a schematic top view of a rotary fill machine according tothe present invention.

FIGS. 14-16 are examples of fill machines according to the presentinvention.

FIG. 18 a is an elevational view of a pouch with an overlap flat seam ina side gusset, according to the present invention.

FIG. 18 b is a detail view of the overlap flat seam in side gusset,according to the present invention.

FIG. 18 c is another detail view of the overlap flat seam in sidegusset, according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to FIGS. 1-11 and 18, a flexible pouch 10 is illustrated. Thepouch 10 may be filled with a product (not shown) and sealed. Varioustypes of products are contemplated, such as a dry product or a fluidproduct. In addition, the product may be a food item, or a non-fooditem. It is contemplated that the pouch may contain a single portion ormultiple portions of the product. In this example the product is acarbonated product.

The flexible pouch 10 is preferably formed from a roll of preprintedmaterial of laminate layers. The laminate material is typically a three,or four, or five gauge material, and is non-limiting. The outer layer isusually preprinted. Alternatively, at least a portion of the materialmay be not printed, i.e. translucent, in order to view the contentscontained therein, as shown in FIGS. 6 a and 7 at 98 as a window. Theclear portion could be in a gusset or insert.

The choice of sheet layer material is non-limiting, and is influenced byfactors such as the product contained in the pouch, the shape of thepouch, or the anticipated use of the pouch. One example of a laminatematerial structure includes at least one layer of virgin polyethyleneterphalate (PET), at least one layer of aluminum foil and another layersuch as EVOH, PET, polyethylene or nylon or the like. Another type oflaminate material structure may also include a metalized foil paperlayer laminated to a cast polypropylene layer and another layer of PET,polyethylene or EVOH. Similarly, the laminate structure may include acast polypropylene (CPP) layer, a polyethylene (PET) layer, a foil (AL)layer, a nylon (ONO) layer and another CPP layer. Another structure isthe use of nylon, foil, nylon and cast polypropylene (ONO/AL/ONO/CPP) orCPP/NY/AL/CPP. Material structures that include CPP are well-suited forpackaging a beverage, such as beer, wine or other carbonated fluids, toadd strength to the walls of the pouch, preserve the carbonation, andprotect the AL layer from cracking. Carbonation is beneficial since itacts as a microbiocide and preserves the flavor and aroma of theproducts. The use of cast polypropylene laminate material also assistsin retaining the filled shape of the container, even as the product isremoved from the pouch 10. The pouch 10 may have a generally cylindricalshape, similar to a traditional metal can, although other shapes arecontemplated, as shown in FIGS. 5-10. A further example of a laminatematerial structure is CPP/AL/ONO/PE. This structure works well when theproduct has a short shelf life, and the nylon eliminates stretching orcracking of the AL layer.

The formed pouch includes a front wall 12 and a back wall 14. Each wall12, 14 is further defined by an upper edge 16, an opposed lower edge 18,and side edges 20 extending therebetween the upper and lower edges 16,18. The side edges 20 are joined along a flat seam 50. In an example ofa pouch formed using a single panel 48 of material, the side edges 20are joined along a flat center seam. In an example of a pouch formedusing two sheets of material, the edges are joined along two flat sideseams. The panel 48 has an inner surface 24 that is adjacent theproduct, and an outer surface 22.

In an embodiment of a pouch 52 illustrated in FIGS. 2 a-2 c, the flatseam 50 is a folded seam or reverse seal. A first and second side edgeincludes a fold, as shown at 54 and 56. The first fold 54 forms anobtuse angle along the first edge and the second fold forms an acuteangle 56 along a second edge 56. It should be appreciated that only aminimal portion of the first side edge 54 extends beyond the second sideedge 56. The first side edge 54 is positioned over the second side edge56, so that the folds are in alignment and that a portion of the firstside edge 54 extends beyond the second side edge 56, as shown at 58. Thefirst and second edges 54, 56 are sealed together in a manner to bedescribed, and the extending edge 58 is folded over to form a flap 60that can lie flat against the outer wall of the pouch 52. Preferably,the flap 60 is secured to the outer wall of the pouch 52. For example,the flap 60 may be secured along an upper edge and a lower edge to thewalls of the pouch. Alternatively, the length of the pouch may besecured to the walls of the pouch. The flap can be secured using asealing means, such as a tack seal, or an adhesive or monolayer film orthe like. In another alternative, the flap may be sealed to the outersurface of the pouch using a second strip 92 of material covering theseam, as shown in FIG. 5. The seam cover 92 is secured using a sealingmeans, such as a weld or an adhesive. The folded seal is advantageous,since it has a higher seal bond strength than a typical layer on layerseal.

Another embodiment of a pouch 62 with an overlap flat seam isillustrated in FIGS. 3-4. In this example, a first side edge 64 overlapsa second side edge 66 a predetermined amount. Alternatively, each sideedge 64, 66 may include a corresponding fold, as shown at 64 and 66 inFIGS. 18 a-18 c. The first side edge 64 is positioned over the secondside edge 64 so that the edges overlap. Preferably, the amount ofoverlap is between 5-12 mm. The first and second edges are sealedtogether using a technique to be described. It should be appreciatedthat the inclusion of a CPP layer of material on the inside of the pouchand on the outside improves the seal strength of the overlap seal, sinceit has a higher bond strength and prevents delamination.

The pouch 10 may include an insert, sidewall or gusset 70. The gusset 70may be integrally formed in the panel 48, as shown in FIGS. 3 and 4, ora separate piece of material. The gusset may be disposed between thefront and back walls, and positioned between the side edges of thewalls, the lower edges, the upper edges, or any desired combination. Itshould be appreciated that the shape of the gusset 70 is nonlimiting.For example, the gusset 70 may be generally wider at one end and taperupwardly towards the opposite end. The gusset 70 may also be of auniform width. The use of the gusset 70 may be functional, i.e. it mayallow the pouch 10 to acquire another shape, such as cylindrical, or tostand upright. The gusset 70 also enhances the strength and rigidity ofthe pouch 10 during filling and processing. A side gusset isadvantageous since it allows the walls of the pouch to expand as theinternal pressure within the pouch increases. A gusset 70 positionedbetween the lower edges of the pouch 10 form a base, which may enablethe pouch 10 to stand upright.

Similarly, the pouch may include an insert, as shown in FIGS. 6-9. Theinsert 72 is a generally planar member that is inserted between thewalls 12, 14 of the pouch 10. The shape of the insert 72 is nonlimiting,and generally influences the shape of the flexible pouch. The insert 72may be positioned internally within the pouch or externally. Variousmaterials may be utilized for the insert, such as foil, cardboard,plastic, nylon, laminate or the like. Further, the insert 72 may beformed from a printed material, or it may be clear. In one example, theinsert 72 is inserted between the lower edges of the panel and sealed tothe walls of the panel. The seal may be an ultrasonic seal or a heatweld or the like.

Referring to FIG. 7, a pouch with two inserts is illustrated. In thisexample, there is a first insert 72 a positioned between the lower edgesof the panel, and a second insert 72 b positioned between the upperedges of the panel. The first insert 72 a may include an integralfitment means, such as a straw hole 80 for receiving a straw. The pouchof this example has a generally square shape. As shown in FIGS. 6 a-6 c,the insert has a round shape and the pouch has a tapered shape.Similarly, in FIGS. 9 a-9 c, the insert has a square shape and thefinished pouch has a tapered shape similar to a bottle.

The pouch 10 incorporates an opening means 74 for accessing the contentsof the pouch. Various types of opening means 74 are known in the art forthis purpose. It should be appreciated that the opening means 74 may beincorporated into the pouch 10 prior to filling the pouch 10. Oneexample of an opening means is a tear-off portion 76, as shown in FIG.6. The tear-off portion 76 usually has an integral tear notch 78. Thetear notch is typically formed near the upper edge, for accessing theproduct contained therein although it could be located elsewhere.Another example of an opening means 74 is a weakened, straw-pierceableportion 80 in the pouch for receiving a straw. A further example of anopening means 74 is a pull tab 82 covering an opening in the pouch. Bothare illustrated in FIG. 7. Yet another example of an opening means is aresealable zipper, such as a hermetic seal.

Still a further example of an opening means 74 is a removable andreplaceable cap 84 secured to a fitment 86. The cap 84 screws onto aspout end 88 of the fitment 86. The cap 84 can be the traditional roundshape. Alternatively, the cap 84 can have an elongated oval shape sothat the pouch may stand up on its own, as shown in FIGS. 11 a-11 d. Thecap 84 and fitment 86 can be made from a variety of materials. Forexample, the cap 84 may be made from plastic, such as reground resins.The fitment 86 may be made of polypropylene (PP), depending on theproduct. The fitment 86 is sealed into the upper edges of the panelusing a sealing means, such as an ultrasonic seal or a heat weld, or thelike. The spout portion of the fitment 86 may include a removable seal90 to prevent leakage of the product or evidence of tampering.

It should be appreciated that the flexible pouch 10 may advantageouslyinclude other features that are known in the art. For example, theflexible pouch 10 may include a guide pocket 24 formed in a wall 14, 16of the pouch 10 prior to filling and sealing, to facilitate theseparation of the front and back walls 14, 16 prior to the filling ofthe pouch 10. An example of such a pouch is disclosed in commonlyassigned U.S. patent application Ser. No. 10/310,221.

It is contemplated that the pouch 10 may undergo a secondary processafter it is filled with the product. For example, the filled pouch maybe frozen. Alternatively, the filled pouch may be pasteurized. Examplesof pasteurized food products include dairy products such as milk, ormeat products such as chicken or the like.

It is contemplated that the flexible pouch 10 may incorporate any of theabove-described features in any combination. For example, the pouch 10may include an insert 72 in the bottom portion of the pouch and atapered top portion, or an insert 72 in the bottom portion of the pouchand a fitment 86 and cap 84 in the top portion of the pouch, or aninsert 72 in the bottom portion and the top portion of the pouch. Inaddition, the finished pouch may assume various shapes, such ascylindrical, cubical, and conical or the like, as influenced by the typeof product and intended usage of the pouch.

Referring to FIG. 12, a method for forming and filling the flexiblepouch 10 using a high-speed machine, such as that described with respectto FIGS. 13-16 is illustrated. The method begins in block 100 at a firststation with the step of forming the body of the pouch. For example, aroll of laminate material, as previously described, is unrolled along ahorizontally oriented plane. The initial width of the roll of materialis determined by the desired finished size of the pouch 10 and thenumber of pouches to be obtained from the width. For example, three orfour or six pouches, representing six to twelve panels, can be obtainedfrom a width of the roll of material on a three-lane machine orfour-lane machine, respectively. Each panel 48 has an inner surface 24and an outer surface 22. One layer of the material is preferablypreprinted with information or locating indicia (not shown), such as aregistration mark. The registration marks are located on the material todenote an edge of a wall 12, 14. The registration marks are read by anoptical reading device (not shown), such as a scanner, to index thematerial in a predetermined position at the cutting station. Thepreprinted information may include labeling information that describesthe product contained within the pouch. In this example, the layer ofpreprinted information is located on an outer layer of the material. Anexample of a high speed, multiple lane machine for forming a pouch isdescribed in commonly assigned U.S. Provisional Patent Application Ser.No. 60/652,338, which is incorporated herein by reference.

The methodology advances to block 105 and a feature, such as a gusset 70or insert 72 is optionally positioned between the aligned first andsecond unrolling sections of material. In addition, an opening means maybe applied at this time. For example, an opening means 74, such as apress-to-close zipper may be positioned between the panels. Anotheropening means such as a straw hole, patch or tear notch may be applied.

The methodology advances to block 110 and the edges of the walls aresealed together to form a flat seam 50. For example, to form a foldedflat seam 52, a fold is formed along an edge of the sheet of material.The angle of the fold is determined, according to the width of seamdesired, as previously described. The fold in the first edge 54 isaligned with the fold in the second side edge 56 and the edges aresealed together, in a manner to be described. The extending edge 58 isfolded over to form the flap and sealed. At least a portion of the flapmay be secured to the outer portion of the material.

To form an overlap flat seam 68, the edges of the sheet of material arepositioned together, such that a first edge 64 overlaps a second edge 68a predetermined amount, and the edges are sealed together. With eitherof these types of flat seams, a second strip of material 92 may bepositioned over the seam and sealed onto the wall of the pouch.

Various techniques are contemplated for sealing the edges together. Forexample, an adhesive may be used to seal the first and second edge ofthe flat seam together. Alternatively, the edges may be sealed using anultrasonic sealing process. Another technique is a heat weld thatincludes the application of heat and compression.

The methodology advances to block 115, and the section of pouches formedin the roll width of material are separated from each other in a cuttingoperation. For example, each section of material may be first separatedalong its width, i.e. along the side seam of the pouches. The section isthen separated into individual pouches. In this example, the width ofunrolling represents the side edges. The material is cut using a knowncutting apparatus, such as a laser or punch or the like. The material iscut into a pouch 10 using a known cutting apparatus, such as a laser orpunch or the like. The cutting apparatus forms a single cut in thematerial to separate the pouches. The length of the pouch 10 iscontrolled by the distance between the cuts.

Alternatively, two pouches 10 are cut out at one time by adding a doublecut 46 between two cuts, preferably in the center. Advantageously,forming two pouches during the cutting operation effectively doubles theassembly line speed.

It should be appreciated that the upper edge or lower edge may befurther trimmed. For example, the end of the pouch may be trimmed toaccommodate a fitment 86. In another example, two legs are formed duringthe trimming operation, in order to recess the fitment. The fitment maybe ultrasonically sealed to the pouch.

The methodology advances to 120, and the lower edge 18 is sealed. Thelower edge 18 may be sealed using a known sealing process, such as anultrasonic sealing process. Another sealing technique is a heat weldthat involves the application of heat and compression. In addition, theflap 60 for a folded flat seam 62 may be tacked down to the outer wallof the pouch, such as at an upper or lower end of the center seam. Theflap is held in place such as by using an adhesive, or sealed whileapplying the heat weld or ultrasonic seal. It should be appreciated thatthe outermost layer of the pouch material may be coated with a heatsealable material to assist in securing the flap to the outer wall ofthe pouch 10.

The methodology advances to block 125 and an opening means 74 may alsobe applied to the pouch 10 at this time. For example, a fitment 86, aspreviously described, may be sealed within the walls of the pouch 10. Inaddition, an insert 72 may be likewise applied to the pouch 10. Theinsert 72 may be positioned at a lower edge of the pouch, an upper edge,or both an upper and lower edge. The methodology advances to block 130.

In block 130, the individual pouches are finished. For example, a loweredge of the pouch 10 may be trimmed to shape, i.e. the corners may beangled. This operation may be performed using a cutter or a die cut orthe like.

In another example of a finishing operation, a crease or guide pocketmay be formed in a top portion of each wall 12, 14 in a creasingoperation, in order to facilitate opening and filling of the pouch. Anexample of a method of forming a crease in a wall to facilitate openingthe pouch is disclosed in commonly assigned U.S. patent application Ser.No. 10/310,221, which is incorporated herein by reference. It should beappreciated that the shape of the finished pouch is non-limiting, andmay be round, square, oval, triangular or the like.

The methodology advances to block 135 and the pre-made pouch 10 is thentransported to the filling machine. The pouches may be loaded into acarrier and transferred to a filling machine. It should be appreciatedthat the filling machine may be integral with the pouch forming machine,or a separate machine. This portability increases the flexibility of thepouch and may result in a manufacturing cost savings.

The methodology advances to block 140, and the pouch is unloaded fromthe carrier and placed in a holder for moving the pouch betweenstations. An example of a holder is a cup-shaped member, as disclosed incommonly assigned U.S. patent application Ser. No. 10/336,601, which isincorporated herein by reference. Alternatively, the pouch 10 may beheld using grippers (not shown) as is known in the art. The methodologyadvances to block 145.

In block 145, the pouch 10 is opened in an opening operation. Varioustechniques are conventionally known in the art for opening the pouch 10.For example, the guide pocket formed by the crease in the front wall 12and back wall 14 facilitates opening of the pouch. A nozzle (not shown)may be mechanically lowered into the guide pocket to direct a stream ofcompressed gas into the guide pocket, to force the walls of the pouch 10away from each other. An example of a gas is carbon dioxide or nitrogen.The blowing station may include a manifold, with a hood extending overthe top of the edges of the pouch as known in the art. The manifold hasrows of apertures (not shown) formed above the upper edges 16 of thepouch 10. The hood is placed over the pouch 10 to assist in maintainingthe air pressure in the pouch 10. The supply of pressurized gas isdirected through the aperture to form a plurality of jets of pressurizedgas or air. The jets are directed downwardly at the diamond-shapedopenings formed at the upper edges 16 to assist in overcoming thesurface tension of the pouch and assist in separation of the walls 12,14. A diving rod (not shown) may then be used to make sure the pouch 10is fully opened. The methodology advances to block 150.

In block 150, the pouch 10 is filled with the product in a fillingoperation. For example, a fill tube (not shown) is lowered into theopened pouch 10 and the product is dispensed into the open pouch 10.

If the product is naturally carbonated, such as beer or soda or thelike, the pouch is preferably filled while immersed in a nitrogenatmosphere. If the product is not naturally carbonated and carbonationis desirable, it is immersed in a carbonator to introduce carbon dioxideinto the product. For example, carbon dioxide is introduced into coldwater or juice to provide a carbonated beverage. The product may containa mixture of up to four volumes of carbon dioxide. It should beappreciated that the carbon dioxide masks any undesirable taste fromketones and other solvents released during the sealing process. Thecarbon dioxide also increases the pressure within the product so thatthe walls of the pouch are rigid after the top is sealed. The product ispreferably filled at a temperature ranging from 29° F. to ambienttemperature. The methodology advances to block 155.

In block 155, the upper edge 16 of the pouch 10 is closed by applying aclosing seal. In this example, the pouch is closed by sealing the upperedges 16 together. The closing seal may be an ultrasonic seal, or anultra pulse seal, or a heat weld or the like: If the pouch holds acarbonated beverage, the pouch may be sealed as described in commonlyowned PCT Patent Application No. PCT/US03/034396 which is incorporatedherein by reference. In the example of a carbonated beverage, the firstseal 94 is an ultrasonic seal or an ultra pulse seal. If desired, an endof the flap flat seam may be tacked down in this operation, or sealedwith the cover strip 92.

In block 160, a second cosmetic seal 96 is applied above the first seal94 for a carbonated product. The second seal may be a heat weld. Some ofthe product may be trapped between the first and second seals 94, 96.This is advantageous since there is no gas in the head space, i.e. theregion between the product and the heat seal, and less pouch material isrequired.

The methodology advances to block 165 and the pouch 10 is finished in afinishing operation. For example, the edges 16, 18, 20 of the pouch 10are trimmed to achieve a predetermined shape. In addition, the pouch 10may be cooled at a cooling station, where the pouch 10 is cooled using aconventionally known cooling technique. The methodology advances toblock 170.

In block 170 the filled pouch 10 is discharged from the machine. Aplurality of pouches may be placed in a package for sales or shippingpurposes.

It should be appreciated that the pouch may undergo other processingsteps, such as such as an upstream oxygen purging station, a downstreamoxygen purging station, pasteurization or the like. For example, thefilled pouch 10 may be pasteurized in integral retort chamber (notshown) that heats and then cools the pouch 10. The pouch 10 may betested, such as burst testing or the like prior to packaging forshipping. These additional processing steps may take place at a stationon the form/fill/seal apparatus, or on another apparatus.

It should be appreciated that the order of steps may vary depending onthe pouch and its features. Also, a particular manufacturing station mayperform one or a plurality of operations, to enhance the efficiency ofthe methodology and apparatus.

Referring to FIGS. 13-16, an example of a fill-seal machine 30 forcarrying out the method described with respect to FIG. 12 isillustrated. The fill machines illustrated are by way of example, andother configurations may be utilized. It should be appreciated that aparticular manufacturing station may perform one or more operations. Itshould also be appreciated that the order of operations may vary. Thefill-seal machine 30 may be configured as a flat bed, a conveyor, arotary turret or the like. An example of a flat bed form machine ismanufactured by Nishibe, such as the model number SBM500, SMB600 orSMB700. It should be appreciated that the fill-seal machine may beintegral with the form machine, or a separate machine.

In operation, the carrier with the pouch is loaded onto the machine 30as shown at “1”. The pouches 10 are removed from the receptacle andplaced in a holder as shown at “2”, such as by using a gripper.

The pouch 10 is transported along the conveyor belt to operation “3”,and the pouch 10 is opened in an opening operation. Various techniquesare conventionally known in the art for further opening the pouch 10.The guide pocket formed by the crease in the front panel and back panelfacilitates opening the upper edges of the pouch. For example, a nozzlemay be mechanically lowered into the pouch to direct a stream ofcompressed gas downwardly into the pouch to force the walls of the pouchaway from each other to further open an upper edge of the pouch. Anexample of a gas is carbon dioxide or nitrogen. The lever arms assist inmaintaining the pouch in an open position.

The pouch 10 is then fully opened. For example, a blowing station mayinclude a manifold, with a hood extending over the top of the edges ofthe pouch. The manifold has rows of apertures (not shown) formed abovethe upper edges of the walls of the pouch. The hood is placed over thepouch to assist in maintaining the air pressure in the pouch. The supplyof pressurized gas is directed through the aperture to form a pluralityof jets of pressurized gas or air. The jets are directed downwardly atthe diamond-shaped openings formed at the upper edges to assist inovercoming the surface tension of the walls and assist in separation ofthe walls. A diving rod may then be used to make sure the pouch is fullyopened.

The opened pouch is transferred to a filling station as indicated atoperation “4”, and the pouch is filled with the product. For example, anozzle dispenses a predetermined amount of product into the openedpouch. The product may be dispensed into the opened edges of the pouchor through a fitment. In this example, the fill nozzle is lowered intothe opened pouch, and the product is dispensed into the open pouch.Depending on the size of the pouch, there may be two fill stations.

If the product is naturally carbonated, such as beer or soda or thelike, the pouch is preferably filled while immersed in a nitrogenatmosphere. If the product is not naturally carbonated, it is immersedin a carbonator to introduce carbon dioxide into the product. Forexample, carbon dioxide is introduced into cold water or juice toprovide a carbonated beverage. The product may contain a mixture of upto four volumes of carbon dioxide. It should be appreciated that thecarbon dioxide masks any undesirable taste from ketones and othersolvents released during the sealing process. The carbon dioxide alsoincreases the pressure within the product so that the walls of the pouch10 are rigid after the top is sealed. The product is preferably filledat a temperature ranging from 29° F. to ambient temperature. Thecarbonation is advantageous as a microbiocide which can enhance theflavor or prevent mold or contamination.

The pouch 10 is transferred to a station “5” for removing any oxygenfrom the pouch. The pouch is then transferred to a sealing station andthe open edges of the pouch are first sealed, as indicated at operation“6”. For example, at the sealing station “6”, the lifting surface ends,causing the lever arms to return to their original position, and thepouch to close. It should be noted that the filled pouch might return toa partially closed position due to the product contained therein. Thefirst may be a thermal seal. For example, a heat-sealing member extendstherethrough the slots in the sides of the cup, to seal the upper edgeof pouch.

Another example of a first seal for a carbonated product utilizes anultrasonic sealing process. Preferably the ultrasonic seal includessound waves and is formed using a horn and anvil. A second seal isapplied at a second sealing station “7”. The second seal may be appliedusing a heat seal means to form a second heat seal over the first seal.It should be appreciated that the second seal may be spaced slightlyabove the first seal. The second heat-sealing station is conventionaland utilizes heat or a combination of heat and pressure to form theseal. The second seal may also be a cosmetic seal or another type ofseal, such as ultrasonic, ultra pulse or the like. The first and secondseals are applied for a carbonated product as disclosed in commonlyassigned Patent Application No. PCT/US03/34396, which is incorporatedherein by reference.

The pouch is transferred to a finishing station as shown at “8” forfinishing and removal from the filling machine. For example, thepasteurized pouch 10 may be cooled. A tear notch may be formed in thepocket portion of the pouch to facilitate opening the pouch to accessthe product in the pouch. In another finishing operation, the edges ofthe pouch are trimmed to achieve a desired shape. The finished pouchesmay be discharged into a package. For example, grippers may be utilizedto place the pouch in a box for shipment.

If desired, the pouch may be transferred to a pasteurization station.Pasteurization enhances the shelf life of the product. The pouch isinserted into an enclosed retort chamber. Air is extracted from thechamber, such as using a vacuum source. The product inside the pouch ispasteurized. For example, a combination of steam and water is used toheat the pouch to a predetermined temperature for a predetermined periodof time to pasteurize the product contained within the pouch. Thepackage is then cooled. In this example, recirculated water surroundsthe pouch to cool the pouch. In certain instances, it may be desirableto apply steam to sterilize the pouch 10 and to wet the inner surface ofthe walls to facilitate handling.

Referring to FIGS. 14-16, another example of a machine for carrying outthe above-described method are illustrated. As shown in FIG. 16-17, themachine 160 is of a turret-type having radially extending arms 162. Eacharm 162 carries a predetermined number of cuplike receptacles 164. Asshown in FIG. 17, the receptacles 164 have a cylindrical wall extendingupwardly from a bottom, as disclosed in co-pending patent applicationSer. No. 60/345,230. There may be up to ten receptacles 164 on each arm162. It should be appreciated that a particular manufacturing stationmay perform one or more operations. It should also be appreciated thatthe order of operations may vary.

The cups are delivered to a loading station by conveyor where emptypouches are loaded into the receptacles from magazines 166 onto a rotaryturret 163. The pouches 10 are fully formed but the upper edges 16 ofthe walls 12, 14 are unsealed. Each magazine 166 or turret segment holdsa supply of empty flat pouches 10. The same number of magazines orsegments are needed as the number of receptacles 164, which will beloaded onto the arm 162 of the turret. The magazines are positioned sideby side with the receptacles 164 below. A linear cam servo feed-indevice 168 moves to push an empty pouch 10 from the magazine 166 into areceptacle 162 positioned beneath the, magazine 166. The cam 170 engagesthe top pouch. The magazines are angled so that gravity pulls thepouches 10 downwardly to the cam 170 which pushes against the bottompouch in the magazine and is rotated to slide the pouch from themagazine downwardly into the corresponding awaiting receptacle 164. Thecams 170 are mounted to a single rod 172 which is rotated to move thecams in unison. The rotary turret picks a pouch 10 horizontally from themagazine 166 and loads onto a segment which transfers the empty pouchinto the receptacle 164.

The group of receptacles 164 is then fed by the conveyor 174 sidewaysonto a radial arm 162 of the turret 163. The arms 162 are sequentiallyindexed through a number of stations. The turret 163 is rotated to movethe receptacles 164 containing the pouches 10 to an opening station 176where the flat pouches 10 are opened by a group of nozzles positionedabove the pouches 10. The pouches 10 then are moved to a checkingstation where photocells or pressure is used to make sure the poucheshave been opened, 178. The pouches 10 then move to a first fillingstation 180 where pouches could be evacuated and diving nozzles arelowered into the pouch 10 to fill the pouch 10 with the product. In thecase of larger pouches, it may be necessary to move the pouches to asecond fill station 182 to complete the filling of the pouch. Thepouches 10 then are moved to a station 184 where any oxygen in the pouchresiding above the product is removed, if necessary. This can be done byproviding a hood or diving nozzle where oxygen is either evacuated orreplaced with carbon dioxide or nitrogen into the pouch to displace theoxygen. A diving nozzle is used to inject the gas.

The pouches 10 are then moved to a pouch closing station 186 to entirelyseal the pouch. For example, an ultrasonic sealing apparatus pushes theupper edges 16 of the walls 12, 14 together over the product and sealsthe walls 12, 14 together. For a carbonated product, a first seal may bean ultrasonic seal and a second seal is applied above the first seal.The second seal is a heat weld, and some of the product may be trappedbetween the first seal and the second seal. For a noncarbonated product,the seal may be a heat weld, ultrasonic seal or the like. The pouchesare then moved to a finishing station 188. The pouches 10 may be cooled.The pouches may undergo a secondary operation, such as pasteurization ata pasteurization station 190.

The pouches are moved to a discharge station 192 where the receptacles164 are moved from the arm 162 of the turret 163 outwardly onto theconveyor 174. The receptacles 164 are then moved by the conveyor 174under robotic arms 194 having grippers which are then lowered to grabthe pouch 10 and lift the pouch 10 from the receptacles 164. Thereceptacles 164 are then moved by the conveyor 174 through a rinsingstation 196 and returned to the other side of the turret for use. Thepouches 10 are placed by the grippers into cartons. At this point, thefilled pouch is available for distribution. Alternatively, the filledpouch 10 may be placed onto another conveyor belt for additionalprocessing, such as tunnel pasteurization for shelf stabilization. Incertain instances, it may be desirable to apply steam to sterilize thepouch 10 and to wet the inner surface of the walls to facilitatehandling.

As shown in FIGS. 14-15, the pouches 10 may be filled using an exampleof a continuous motion machine 210. The continuous motion machine hasrows 212 of receptacles 164 mounted to a conveyor which are moved in anelliptical path past the same stations as set forth for the rotarymachine above. Up to ten receptacles may extend across a row. Preformedpouches are fed from magazines located above the receptacles.

The various operations such as opening, checking, filling and sealingare performed by apparatus which moves over the receptacles at the samespeed as the receptacles. Two sets of identical equipment such asopening equipment are utilized. The first set travels with the beltperforming the operation while a second set is lifted upwardly by achain along a frame and then moved rearwardly and down to the startposition where it meets the next row of receptacles. The pouches areloaded into the receptacles and then moved to the start of the openingstation 214 where blowers are moved down and travel with the poucheswhile the alternate set of blowers are moved upwardly and rearwardly. Atthe end of the travel through the opening station, the pouches are fullyopened by diving wands 216. The pouches are then turned 180° to travelback down through the apparatus where they are moved sequentiallythrough an evacuation station 218, fill station 220, closing station 222and top seal station 226. At the opposite end of the machine, therobotic arms 228 move downwardly, grab the pouches and move them to aconveyor for loading into packaging. The pouches then are rotated 180°to the start position and the receptacles may be washed as they movearound to the start position.

The present invention has been described in an illustrative manner. Itis to be understood that the terminology which has been used is intendedto be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possiblein light of the above teachings. Therefore, the present invention may bepracticed other than as specifically described.

1. A flexible pouch with a flat seam for containing a product, said pouch comprising: a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween, wherein said side edges are joined together by a folded flat seam that lies flat against said outer surface of said panel such that one side edge includes a fold forming an obtuse angle extending transversely along the first side edge and the second side edge includes a fold forming an acute angle extending transversely along the second side edge, and the first side edge is positioned over the second side edge so that the first fold along the first side edge is aligned with the second fold along the second side edge, and a portion of the first side edge extends beyond the second side edge, and the extending first side edge is folded over the second side edge and sealed; and an opening means integrally formed in said panel for accessing a product contained within the pouch.
 2. The pouch as set forth in claim 1 wherein said pouch includes a gusset.
 3. The pouch as set forth in claim 1 wherein said gusset is integrally formed in said panel.
 4. The pouch as set forth in claim 1 wherein said pouch includes a front wall and a back wall and an insert positioned between said front wall and said back wall.
 5. The pouch as set forth in claim 4 further including a strip of material sealed over said flat seam.
 6. The pouch as set forth in claim 1 wherein said opening means includes a fitment and a cap removably attached to said fitment.
 7. The pouch as set forth in claim 1 wherein a base portion of said removable cap has an oval shape for supporting said cap in an upright position.
 8. A flexible pouch with a flat seam for containing a product, said pouch comprising: a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween, wherein said side edges are joined together by an overlap flat seam that lies flat against said outer surface of said panel such that a first side edge overlaps a second side edge a predetermined amount; and an opening means integral with said panel for accessing a product contained within the pouch.
 9. The pouch as set forth in claim 8 wherein said pouch includes a gusset.
 10. The pouch as set forth in claim 9 wherein said gusset is integrally formed in said panel.
 11. The pouch as set forth in claim 8 wherein said pouch includes a front wall and a back wall and an insert positioned between said front wall and said back wall.
 12. The pouch as set forth in claim 8 further including a strip of material sealed over said flat seam.
 13. The pouch as set forth in claim 8 wherein said opening means includes a fitment and a cap removably attached to said fitment.
 14. The pouch as set froth in claim 13 wherein a base portion of said removable cap has an oval shape for supporting said cap in an upright position.
 15. The pouch as set forth in claim 8 wherein said first side edge has a fold extending transversely along the first edge, and the first edge is positioned over the second edge, so that the first fold along the first edge overlaps the second edge a predetermined amount.
 16. A method of forming a flexible pouch with a flat seam on a machine, said method comprising the steps of: forming a body of the pouch from a roll of laminate material, wherein the body of the pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween; joining together and sealing the side edges of the panel to form a flat seam that lies flat against the outer surface of the pouch; sealing the lower edge of the panel; applying an opening means to the panel; and finishing the pouch.
 17. The method as set forth in claim 16, further including the steps of: opening the pouch; filling the pouch with the product; carbonating the product; sealing the upper edge of the pouch using an ultrasonic seal; applying a second seal above the first ultrasonic seal; and finishing the filled pouch.
 18. The method as set forth in claim 17 wherein said step of forming the body of the pouch includes the step of forming a plurality of pouches from the roll of material.
 19. The method as set forth in claim 18 further includes the step of separating the pouches using a double cut between the pouches.
 20. The method as set forth in claim 17 further includes the step of pasteurizing the product within the sealed pouch.
 21. The method as set forth in claim 16 wherein said step of joining together the side edges further includes the steps of: forming a fold having an obtuse angle extending transversely along the first side edge; forming a fold having an acute angle extending transversely along the second side edge; positioning the first side edge over the second side edge so that the first fold along the first side edge is aligned with the second fold along the second side edge and a portion of the first side edge extends beyond the second side edge; folding the extending first side edge over the second side edge; and sealing the first side edge to the second side edge.
 22. The method as set forth in claim 16 wherein said step of joining together further includes the steps of: overlapping the first side edge over the second side edge a predetermined amount; and sealing the first side edge to the second side edge.
 23. The method as set forth in claim 16 further including the step of positioning a strip of material over the seam and sealing the material strip to the outer surface of the pouch. 